LARVIN-METHOMYL UPGRADE


Client:

Bayer CropScience

Location

Institute, WV

Augusta Project Number

196073

Value of Project:

$1 M

Contract Amount:

$1.2 M

Status:

Current Project - Completion Date August 2007

Description:

The Larvin-Methomyl Distributed Control System (DCS) Upgrade project installed a new control system for a complex Bayer CropScience chemical manufacturing facility.

Augusta Engineering & Design was responsible for the following activities during the project's detailed design:

  • developed I/O list (1,277 I/O points in Phase I & 830 I/O points in Phase II)
  • used Smart Plant Instrumentation SPI (INtools) to create new loop drawings
  • configured the new DCS
  • planned implementation of the project including different construction phases
  • designed temporary provisions for many loops to support construction and transition
  • implemented hardwired relay logic functions from 400 schematics on the new DCS
  • developed construction work scope specification & provided construction support
  • issued drawings and other documentation as required for construction & check-out
  • facilitated client's review of safety and control interlocks
  • designed the installation of 160 interposing relays

This project involved the following complexities and challenges:

  • supporting continued chemical manufacturing operations for a major part of the facility while the control system for a second part was in construction
  • identifying and tracking 27 distinct construction phases to support operations
  • supporting a very aggressive time schedule that was further accelerated by one month despite an initial construction delay of three weeks
  • adapting to changes in chemical production schedules
  • relocating the control room during the project.